York CodePak YK L1 L1 G4 Operation Manual

Centrifugal liquid chillers styles a & b with microcomputer control center part 371-01200-004 for electro-mechanical starter & solid state starter

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OPERATING & MAINTENANCE

MODEL YK L1 L1 G4

MODEL YK L1 L1 G4 THRU

MODEL YK L1 L1 G4

MODEL YK LB LB G4

MODEL YK LB LB G4 THRU

MODEL YK LB LB G4

WITH MICROCOMPUTER CONTROL CENTER P

WITH MICROCOMPUTER CONTROL CENTER PAR

WITH MICROCOMPUTER CONTROL CENTER P

FOR ELECTRO-MECHANICAL STAR

FOR ELECTRO-MECHANICAL ST

SYSTEM CONTAINS REFRIGERANT UNDER PRESSURE.

SERIOUS INJURY COULD RESULT IF PROPER PROCEDURES ARE

NOT FOLLOWED WHEN SERVICING SYSTEM. ALL SERVICE WORK

SHALL BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN IN

ACCORDANCE WITH YORK INSTALLATION/OPERATION MANUAL.

Supersedes: 160.49-O1 (894)

THRU

THRU YK S2 S2 J4 (STYLES A & B)

THRU

R-22 AND R-134a (COOLING ONLY) Y) Y) Y) Y)

R-22 AND R-134a (COOLING ONL

R-134a (COOLING ONL

R-134a (COOLING ONLY) Y) Y) Y) Y)

R-134a (COOLING ONL

STYLES A & B

CENTRIFUGAL LIQUID CHILLERS

YK S2 S2 J4 (STYLES A & B)

AND

THRU

THRU YK SE SC J2 (STYLE C)

YK SE SC J2 (STYLE C)

THRU

YK SE SC J2 (STYLE C)

ART #371-01200-004

ARTER & SOLID ST

TER & SOLID ST

TER & SOLID STA A A A A TE ST

TER & SOLID ST

27073A

25789A

WARNING

Form 160.49-O1 (197)

T #371-01200-004

TE STAR

TE ST

ARTER

TER

STYLE C

27385A

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Summary of Contents for York CodePak YK L1 L1 G4

Page 1 WARNING WARNING WARNING WARNING WARNING SYSTEM CONTAINS REFRIGERANT UNDER PRESSURE. SERIOUS INJURY COULD RESULT IF PROPER PROCEDURES ARE NOT FOLLOWED WHEN SERVICING SYSTEM. ALL SERVICE WORK SHALL BE PERFORMED BY A QUALIFIED SERVICE TECHNICIAN IN ACCORDANCE WITH YORK INSTALLATION/OPERATION MANUAL.
Page 2: Table Of Contents
STYLE C YK NB PB H1 – CX C DESIGN LEVEL (C) MOTOR CODE: 60 Hz 50 Hz POWER SUPPLY – for 60 Hz 5 for 50 Hz COMPRESSOR CODE G4,H0,H1,H2,J1,J2 CONDENSER CODE LB,LC,MB,MC,NB,NC,PB,PC,QB,QE,RB,RC,SB,SC COOLER CODE LB,LC,MB,MC,NB,NC,PB,PC,PD,PE,QB,QC,QD,QE, RB,RC,RD,RE,SD,SE MODEL YORK INTERNATIONAL...
Page 3: Fundamentals Of Operation
CodePak cooler, where boiling refrigerant absorbs heat from the water. The chilled liquid is then The YORK CodePak is commonly applied to large air piped to fan coil units or other air conditioning terminal conditioning systems, but may be used on other appli- units, where it flows through finned coils, absorbing cations.
Page 4 7619A(D) performance of many different compressors to match DETAIL A – COMPRESSOR PREROTATION VANES various load conditions from full load with vanes wide open to minimum load with vanes completely closed. LD01066 FIG. 2 – REFRIGERANT FLOW-THRU CODEPAK YORK INTERNATIONAL...
Page 5: Section 2 – Microcomputer Control Center
Responsibility for assuring the satisfactory operation of other equipment included in the same power source as the YORK equipment rests solely with the user. YORK disclaims any liability resulting from any interference or for the correction thereof. YORK INTERNATIONAL...
Page 6 • DAILY SCHEDULE (7 DAY TIME-CLOCK PROGRAM- ability to limit motor current via control of the pre-rota- MING) tion vanes. Further, it is compatible with YORK Solid • HOLIDAY State Starter (optional) and electro-mechanical starter • REMOTE RESET TEMPERATURE RANGE applications.
Page 7: Control Center
– or – jumper is not installed, all temperatures are displayed in degrees Centigrade (°C) and all • Press and release appropriate Display key, then press and release the DISPLAY HOLD key – the pressures are displayed in Kilo-Pascals (kPa). YORK INTERNATIONAL...
Page 8 (Solid State Starter Applications Only) ducer (compressor housing). Displayed value includes offset pressure derived from auto-zeroing during “START If chiller is equipped with a YORK Solid State Starter, SEQUENCE INITIATED”. If either transducer is out- use SSS MOTOR CURRENT / VOLTS key to dis- of-range, XX.X is displayed.
Page 9 Use the OPERATING HOURS key as described YORK factory and is checked by the service tech- on page 7, to produce the following message: nician at start-up. For security reasons, a special access code is required to program the line volt- OPER.
Page 10 100%. (See “Programming System Setpoints”, page 14.) HOLIDAY – This key indicates which days in the up- If chiller is equipped with a YORK Solid State Starter, coming week are holidays. On those designated days, the system FLA is also displayed. This value is pro- the chiller will automatically start and stop via the holi- grammed by the factory and should never be changed.
Page 11 If chiller is equipped with a YORK Solid State Starter, the message is: DISPLAYING SYSTEM SETPOINTS CURRENT LIMIT = XXX % FLA;...
Page 12 To Display DATA LOGGER setpoints: the week are sequentially displayed beginning with Sunday and ending with Holiday. The display will con- Refer to YORK, Form 160.49-N2 for operation of tinuously scroll until the DISPLAY HOLD key is again this key.
Page 13 ACCESS TO PROGRAM MODE DISABLED 7. Press PROGRAM key. The Control Center will automatically return to LO- CAL, REMOTE or SERVICE mode ..whichever is displayed. was last selected. PROGRAM MODE, SELECT SETPOINT YORK INTERNATIONAL...
Page 14 CURRENT LIMIT = XXX% FLA; MTR CUR = _ _ _ FLA 2. Use Entry keys to enter desired value. LD01070 NOTE: Motor Current FLA value is entered by YORK factory and checked at system start-up. It cannot be changed without special access code.
Page 15 (MONTH/DAY/YR). If month and day are single digit entries, precede the entry with “0”. For example, 02/04/88. FIG. 9 – KEYPAD – PROGRAMMING “CLOCK” SETPOINT 7. Press and release ENTER key. PROGRAM MODE, SELECT SETPOINT message is displayed. YORK INTERNATIONAL...
Page 16 If you press the 1 Entry key, Monday’s start and SCHEDULE” SETPOINT stop time will be automatically entered for Tues- day through Friday. – or – b. If you press the 0 Entry key, Tuesday through Friday can be programmed with different start and stop times. YORK INTERNATIONAL...
Page 17 3. Press and release ENTER key. PROGRAM MODE, SELECT SETPOINT message is displayed. LD01075 FIG. 12 – KEYPAD – PROGRAMMING “REMOTE RESET” TEMP RANGE To Enter DATA LOGGER Setpoint: Refer to Form 160.49-N2 for operation of this key. YORK INTERNATIONAL...
Page 18 AUTO – Press and release this key to put the pre- be reset with this key, unless the condition still exists. rotation vanes under LCWT control as long as the cur- To reset any cycling or warning message, place the YORK INTERNATIONAL...
Page 19: Operating Modes
(i.e., Energy is displayed. LOCAL OPERATING MODE IN EFFECT Management System) or cycling input. The control sig- nal inputs are: • If the Control Center is in REMOTE mode, is displayed. REMOTE OPERATING MODE IN EFFECT 1. Remote Start YORK INTERNATIONAL...
Page 20 RESET position. Move COMPRESSOR switch from STOP/RESET to START position. Switch will spring-return to RUN NOTE: The operator cannot start the compressor (us- position. ing this switch) when the Control Center is in To STOP compressor: REMOTE mode. YORK INTERNATIONAL...
Page 21 28 PSIG, 193 kPa (R-134a), the vanes will be permit- point. ted to open. Low pressure limit feature is not used when – or – program jumper (JP3) is cut (Brine application). YORK INTERNATIONAL...
Page 22 SYSTEM SHUTDOWN – PRESS STATUS MON XX:XX AM – POWER FAILURE – AUTOSTART Displayed when chiller is shut down on a cycling shut- The chiller is shut down because there has been a YORK INTERNATIONAL...
Page 23 To restart chiller, press This message will be displayed when a remote device COMPRESSOR switch to STOP/RESET position and (typically an Energy Management System) has com- then to the START position. manded the chiller to shut down. The chiller will restart YORK INTERNATIONAL...
Page 24 (CM-2 Electro-Mechanical starter application), or the chiller will be allowed to restart when the oil pressure YORK Solid State Starter initiated a shutdown. To re- decreases to 59 PSID, 406.8 kPa. To restart the chiller, start system, reset the external device that caused the press COMPRESSOR switch to STOP/RESET posi- shutdown.
Page 25 – SSS Motor Current/Volts”, page 10. The system will automatically restart when all phases of line voltage of this period is controlled by the “Prerun” (JP6) wire jumper on the Micro Board as follows: increase to the minimum required starting voltage. YORK INTERNATIONAL...
Page 26 40°F procedure. This special reset procedure is detailed in (22.2°C). YORK Service manual, Form 160.49-M2. Failure to per- form the visual inspection prior to restarting the chiller – or – could result in severe compressor damage!!! 3.
Page 27 Sensor” module and the MicroComputer Control Cen- setpoints will have been lost and must be repro- ter has been disconnected or has a poor electrical con- grammed. Order a replacement RTC IC chip (YORK nection. part number 031-00955-000) from the YORK Parts Dis- tribution Center.
Page 28: Section 3 – System Operating Procedures
The Control Center sup- Holiday = None plies a signal to operate the prerotation vanes. Remote Reset Temp. Range = 20°F (11.1°C) The movement of the vanes will be displayed on Data Logger = No operation YORK INTERNATIONAL...
Page 29 Prerotation Vanes to increase the capacity of faces within the compressor. the unit. YORK INTERNATIONAL...
Page 30 If the load continues to decrease, after the Prerotation Vanes are entirely closed, the CodePak will be shut The YORK CodePak is designed to use less power by down by the Low Water Temperature control (LWT) taking advantage of lower than design temperatures...
Page 31 An optional status printer is available for this purpose closed until the compressor motor is up to speed or Fig. 16 shows a log sheet used by YORK Personnel on the on the run winding; then the vane motor should for recording test data on CodePak systems.
Page 32 6. Check the compressor discharge temperature. Form 160.44-F6 and may be obtained through the nearest Press DATA DISPLAY key. During normal opera- YORK office. Automatic data logging is possible by tion discharge temperature should not exceed 220°F connecting the optional printer and programming the (104.5°C).
Page 33 Micro Board) tinues to hinder the performance of the unit, please • Low Water Temp call the nearest YORK District Office. Failure to report • Flow Switch constant troubles could damage the unit and increase • System Cycling the cost of repairs considerably.
Page 34 If the water the cooling tower, condenser, condenser pump, and systems were drained, fill the condenser water cir- the chilled water system-chilled water pump and cuit and chilled liquid circuit. coils. YORK INTERNATIONAL...
Page 35: Section 4 – System Component Description
DUAL RELIEF VALVES MOTOR COOLER 27073A 27073A DEHYDRATOR REFRIGERANT CHARGING VALVE REFRIGERANT LINE SIGHT GLASSES FRONT VIEW DISCHARGE LINE PRE-ROTATION VANE ACTUATOR OIL PUMP STARTER SUB-COOLER 25717A OIL RESERVOIR/ PUMP CONDENSER OIL COOLER FIG. 17 – SYSTEM COMPONENTS YORK INTERNATIONAL...
Page 36 There are main points within the GENERAL motor-compressor which must be supplied with forced lubrication as follows: The YORK CodePak Centrifugal Liquid Chiller is com- pletely factory-packaged including cooler, condenser, 1. COMPRESSOR DRIVE SHAFT (Low Speed) sub-cooler, compressor, motor, lubrication system, Mi- croComputer Control Center, and all interconnecting a.
Page 37 The compressor motor is an open-drip-proof, squirrel The removable compact water boxes are fabricated of cage, induction type constructed to YORK design speci- steel. The design working pressure is 150 PSIG (1034 fications. 60 hertz motors operate at 3570 rpm. 50 hertz kPa) and the boxes are tested at 225 PSIG (1551 kPa).
Page 38 LD01079 FIG. 18 – SCHEMATIC DRAWING – (YK) COMPRESSOR LUBRICATION SYSTEM YORK INTERNATIONAL...
Page 39: Section 5 – Operational Maintenance
To change the dehydrator, use the following procedure: condenser-gas through the eductor. 1. Shut the stop valves on the condenser gas line, oil LD01080 FIG. 19 – OIL RETURN SYSTEM YORK INTERNATIONAL...
Page 40 134a application. into the system. New YORK Refrigeration oil must be used in the cen- 3. Open the oil charging valve and pump oil into the trifugal compressor. Since oil absorbs moisture when...
Page 41 TABLE 1 – CAUSES OF NORMAL AND SAFETY SYSTEM SHUTDOWNS IN ACCORDANCE WITH THE MICROCOMPUTER CONTROL, CENTER DISPLAY SHUTDOWN CAUSE GOVERNING CONTROL FUNCTION CONTROL CENTER DISPLAY PROGRAMMED START-UP OF PROBABLE CAUSE OPERATING SETPOINTS SYSTEM AFTER AND SERVICE DAY OF TIME OF CAUSE OF METHOD OF POINT...
Page 42 TABLE 1 – CAUSES OF NORMAL AND SAFETY SYSTEM SHUTDOWNS IN ACCORDANCE WITH THE MICROCOMPUTER CONTROL CENTER DISPLAY SHUTDOWN CAUSE GOVERNING CONTROL FUNCTION CONTROL CENTER DISPLAY PROGRAMMED START-UP OF PROBABLE CAUSE OPERATING SETPOINTS SYSTEM AFTER AND SERVICE DAY OF TIME OF CAUSE OF METHOD OF POINT...
Page 43 MON. 10:00 AM Power Micro Board 8.29VDC 7.84 Auto restart plug To restart, press Power Failure Failure undervoltage is removed on compressor switch circuit on 5V Micro Board to STOP-RESET unregulated Position and then to supply START position MON. 10:00 AM Oil Pressure High Oil Press.
Page 44 Cutout. Display reading resevoir and piping due to (Refer to “Charging The System With lowered system pressure. Oil”, page 48.) LOW OIL PRESSURE Burned out oil heater. Replace oil heater. YORK INTERNATIONAL...
Page 45 OIL PRESSURE display key when oil pump runs. Faulty wiring/connectors. 11. SYMPTOM: REDUCED OIL PUMP CAPACITY Oil pump pumping capacity. Excessive end clearance Inspect and replace worn parts. pump. Other worn pump parts. Partially blocked oil supply Check oil inlet for blockage. inlet. YORK INTERNATIONAL...
Page 46: Section 7 – Maintenance
(by means of soap test or leak detector) amount of R-22 mixed with dry nitrogen so that a ha- and repaired. EVACUATION AND DEHYDRATION OF UNIT LD01082 FIG. 21 – EVACUATION OF CODEPAK YORK INTERNATIONAL...
Page 47 100,000 51.1 94.6 66.7 50,000 38.3 98.0 33.3 25,000 25.6 100.0 13.3 10,000 11.1 100.5 6,300 100.6 5,000 101.1 2,000 –9.4 101.2 1,000 –17.2 101.3 .069 –23.9 101.3 .014 –38.9 101.3 .007 –45.6 101.3 .0014 .013 –56.7 101.3 YORK INTERNATIONAL...
Page 48 When this point is reached, practically all of the air limits specified in Step 6 above, the leak must be has been evacuated from the system, but there is still found and repaired. a small amount of moisture left. In order to provide a YORK INTERNATIONAL...
Page 49: Refrigerant Charging
1474 1465 kg) of refrigerant. These drums are not returnable and they should be stored for future use if it should ever 3500 3500 1588 1588 become necessary to remove refrigeration from the 3850 3840 1746 1742 system. YORK INTERNATIONAL...
Page 50: Checking The Refrigerant Charge
(see Fig. 23); ambient temperature after 24 hours of idle these readings are to be interpreted using the graph standby. shown in Fig. 24. LD01085 FIG. 23 – DIAGRAM, MEGGING MOTOR WINDINGS YORK INTERNATIONAL...
Page 51 FORM 160.49-O1 TEMPERATURE – °F (°C) LD01086 FIG. 24 – MOTOR STATOR TEMPERATURE AND INSULATION RESISTANCES YORK INTERNATIONAL...
Page 52 In many major cities, commercial organizations now toms may also be due to foul gas buildup. Purging will offer a specialized service of acid cleaning coolers remove the foul gas revealing the effect of fouling. and condensers. If acid cleaning is required, YORK YORK INTERNATIONAL...
Page 53 A continuous buildup of NOTE: Do not use carbon tetrachloride for this pur- bubbles around a tube indicates a tube sheet leak. YORK INTERNATIONAL...
Page 54 YORK office to request the presence Internal wearing of compressor parts could be a seri- of a YORK Service man.
Page 55: Section 8 – Preventive Maintenance
YORK will not be liable for costs incurred of the condenser and cooler in a clean condition. to return the system to satisfactory operation.
Page 56 2. It is important that the factory settings of controls that may be obstructing the jet. (operation and safety) not be changed. If the set- tings are changed without YORK’s approval, the warranty will be jeopardized. ELECTRICAL CONTROLS 3. A 5-11 year life battery is part of the RTC-Real 1.

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York CodePak YK L1 L1 G4 Operation Manual

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